Modular shipping and display pallet

ABSTRACT

A modular pallet assembly including a plurality of stackable shelves, each shelf having a plurality of vertical supports and at least one divider extending between adjacent vertical supports, the adjacent vertical supports being selectively spaced for receiving a desired product. The vertical supports include a plurality of locking grooves and the dividers include a locking hook on each opposing end, such that each locking hook engages a corresponding locking groove on the adjacent vertical supports and thereby defines a predetermined pallet configuration.

TECHNICAL FIELD

The present invention is directed to a pallet, more particularly to a pallet for use during both shipping and display of a product, and still more particularly, to a modular pallet having movable dividers which allow for packaging of a plurality of predetermined product sizes.

BACKGROUND

Packaging cartons, pallets, containers, and the like, are well known in the art which allow for products to be palletized at the manufacturing facility, shipped to a retailer, and then displayed for purchase at the point of sale while still within the original packaging pallet. Over the years, retailers have recognized the advantages of having an attractive free-standing display for merchandizing a product, while at the same time reducing the labor required to unload the products and arrange the same on store shelves. The advantages achieved apply to many different types of products, each of which are unique in shape and size.

Even within a single product line, various sizes of products need to be accommodated. By way of example, within the toy industry, board games are generally provided in a paperboard box have four sides, a top, and a bottom. The dimensions of the box, however, may be a long, short rectangle, a short, tall rectangle, or a square of any dimension, for instance. Thus, for each differently shaped game box, a specific pallet configuration was required in order to package, ship and display the game. Accordingly, special tooling was required for each desired pallet configuration,

While shipping and display pallets, i.e., merchandizing pallets, have enjoyed increasing commercial success, the requirement for customized tooling substantially increases the pallet costs and the volume of inventory that must be maintained. Accordingly, there exists a need in the marketplace for a merchandizing pallet which is able to accommodate a plurality of product dimensions.

SUMMARY

These and other objects are met by a modular pallet assembly comprising a plurality of stackable shelves, each said shelf including a plurality of vertical supports and at least one divider extending between adjacent said vertical supports. In a preferred embodiment, said adjacent vertical supports are selectively spaced for receiving a desired product. The vertical supports include a plurality of locking grooves and the dividers include a locking hook on each opposing end such that the locking hooks engage corresponding locking grooves on the adjacent vertical supports and thereby define a predetermined pallet configuration. In a preferred embodiment, the vertical supports further include a lower slot and the dividers further include a lower tab, the lower tab engaging the lower slot to further secure engagement of the dividers with the vertical supports.

According to a further embodiment, a pallet for shipping and displaying a product comprises a bottom skirt, at least one lateral shelf disposed within the bottom skirt, a plurality of vertical supports disposed within each of the lateral shelves, and at least one divider disposed between adjacent vertical supports. Each of the vertical supports includes a plurality of upper locking grooves and each divider includes an upper locking hook extending from an upper edge on each end thereof, thus, the upper locking hook engages one of the upper locking grooves on adjacent vertical supports to thereby removably lock together the dividers and the vertical supports in a desired configuration. Still further preferred, each of the vertical supports includes a lower slot and each of the dividers includes a lower tab, wherein the lower tab is dimensioned for insertion into the lower slot.

Another aspect of the invention provides a method of assembling a modular pallet comprising forming a lateral shelf; forming a plurality of vertical supports; positioning said plurality of vertical supports within the lateral shelf with a desired distance between adjacent said vertical supports to receive a predetermined product; and inserting at least one divider between adjacent vertical supports to as to maintain the desired distance. According to a preferred method, inserting the at least one divider includes aligning a locking hook on the divider with a locking groove on the vertical support such that the locking hook engages a wall of the locking groove.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

These and other objects, features, and advantages of the present invention will become more readily apparent to those skilled in the art upon reading the following detailed description, in conjunction with the appended drawings in which:

FIG. 1 is a perspective view of a modular shipping and display pallet according to a preferred embodiment of the invention.

FIG. 2 is a perspective view thereof according to a second configuration, with product loaded therein.

FIG. 3 is perspective view of a preferred shelf thereof.

FIG. 4 is a perspective view of preferred shelves thereof, with product loaded therein.

FIG. 5. is a top plan view of a preferred shelf configuration.

FIG. 6. is a top plan view of a further preferred shelf configuration.

FIG. 7. is a plan view of a blank for the pallet skirt thereof.

FIG. 8 is a plan view of a blank for the lateral shelf thereof.

FIG. 9 is a plan view of a blank for a vertical support thereof according to a preferred embodiment.

FIG. 10 is a plan view of a blank for a vertical support thereof according to a further preferred embodiment.

FIG. 11 is a plan view of a blank for a vertical support thereof according to a further preferred embodiment.

FIG. 12 is a perspective view of a stack of dividers thereof showing a preferred end configuration, the other end of each divider preferably being a mirror image thereof.

FIG. 13 is a plan view of a blank for a top support thereof according to a preferred embodiment.

FIG. 14 is a plan view of a blank for a top support thereof according to a further preferred embodiment.

FIG. 15 is a plan view of a top connector thereof.

FIG. 16 is a plan view of a finishing end panel thereof.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 1-4, a modular shipping and display pallet according to a preferred embodiment of the invention is shown generally by reference numeral 10. Modular pallet 10 preferably includes a bottom skirt 12 extending around the perimeter thereof. A plurality of lateral shelves 14, each having a plurality of vertical supports 16, 18, and/or 20 disposed therein, are arranged within the skirt 12. The vertical supports define rows for receiving a product within the shelves 14 and dividers 22 are disposed perpendicular to the vertical supports so as to define the dimensions of the desired receiving areas for the products. Modular pallet 10 preferably includes a top panel 28 and a finishing end panel 30 in order to provide an aesthetically pleasing merchandising display. The end panel and/or top panel may include graphic designs indicating the product within the modular pallet.

FIGS. 5 and 6 illustrate possible configurations for lateral shelf 14 utilizing vertical supports 16, 18 and 20. As shown, product “A”, i.e., game boxes “A”, having a first dimension, product “B”, i.e., game boxes “B”, and product “C”, i.e., game boxes “C”, can be intermixed within a shelf 14 merely by selectively choosing vertical support 16, 18 or 20 and positioning the same at the appropriate position. After the product is loaded into each shelf, top supports 24, 26 are preferably disposed as shown in order to provide further strength and rigidity to the palletized load.

Referring to FIG. 7, a blank for the pallet skirt 12 is shown. According to the illustrated embodiment, a blank having W×L dimensions of 44.5″×44.5″ will form a 36.5″×36.5″ skirt, and thus generally define a 36″×36″ modular pallet 10, when folded along the score lines (shown in broken lines). Additional preferred dimensions for modular pallet 10 are 24″×40″ and 48″×48″, although one skilled in the art will appreciate that any size pallet could be formed depending upon the configuration of the product which is to be contained therein.

FIG. 8 illustrates a blank for a lateral shelf 14 which is disposed within the pallet skirt 12 after folding along the illustrated score lines. The lateral shelf 14 forms the base upon which the products will be loaded.

FIGS. 9-11 illustrate vertical supports 16, 18, 20 in accordance with a preferred embodiment of the invention. When folded along the score lines to form the final configuration, each of the vertical supports 16, 18, 20 define a rectangular, box-like structure having a plurality of upper locking grooves 32 and lower slots 34. With respect to vertical support 20, upper locking groove 32 may include opposing grooves 32 a, 32 b on an upper surface thereof.

FIG. 12 illustrates an end portion of divider 22, it being understood that the other end is preferably a mirror image thereof. Divider 22 includes an upper locking hook 36 at an upper end edge and a lower projecting tab 38 disposed therebelow. As shown in FIGS. 1-4, lower projecting tab 38 is inserted into lower slot 34 of a vertical support 16, 18, 20 and locking hook 36 is then disposed within upper locking groove 32 of the vertical support. In a preferred embodiment, the upper locking hook 36 forms a recessed area 40 between the end edge of the divider 22 and the inwardly facing edge of the hook 36. Accordingly, when hook 36 is disposed within locking groove 32, the bottom edge 42 of the groove is received within the recessed area 40; thereby removably locking the dividers 22 with the vertical supports 16, 18, 20.

FIGS. 13 and 14 illustrate blanks for the top supports 24, 26 shown in FIGS. 5 and 6, the width of supports 24 and 26 differing in order to accommodate various configurations formed by the vertical supports and dividers. Top supports 24, 26 are folded along the score lines (shown in solid lines) such that after the products are loaded within each shelf 14, the top supports 24, 26 are disposed thereover and held in place by insertion of the projecting blank tabs into the locking grooves 32. The top supports 24, 26 further enhance the stability and overall strength of the loaded pallet.

In order to provide an attractive display, modular pallet 10 preferably includes a top finishing panel 28 disposed over the uppermost shelf and finishing end panels 30 on the opposing sides of the pallet 10. The end panels 30 and/or the top panel 28 may include colorful, eye-catching graphics to enhance consumer attention.

While the present invention has been described with respect to the preferred embodiments thereof, this is by way of illustration for purposes of disclosure rather than to confine the invention to any specific arrangement as there are various alterations, changes, deviations, eliminations, substitutions, omissions and departures which may be made in the particular embodiment shown and described without departing from the scope of the claims. 

1. A pallet for shipping and displaying a product, said pallet comprising: a bottom skirt; at least one lateral shelf disposed within the bottom skirt; a plurality of vertical supports disposed within each said lateral shelf; at least one divider disposed between adjacent said vertical supports; wherein each of said vertical supports includes a plurality of upper locking grooves; wherein each said divider includes an upper locking hook extending from an upper edge on each end thereof, said upper locking hook engaging one of said upper locking grooves on adjacent said vertical supports to thereby removably lock together said dividers and said vertical supports in a desired configuration.
 2. The pallet of claim 1, wherein each said vertical support further includes a lower slot and each said divider further includes a lower tab, said lower tab being dimensioned for insertion into said lower slot.
 3. The pallet of claim 1, wherein said vertical support includes opposing side walls and an upper surface, said locking groove extending across said upper surface from one of said opposing side walls to the other of said opposing side walls.
 4. The pallet of claim 1, wherein said vertical support includes opposing side walls and an upper surface, said locking groove defining a first groove and a second groove, said first groove extending partly across said upper surface and said second groove extending partly across said upper surface such that a portion of said upper surface remains intact between said first groove and said second groove.
 5. The pallet of claim 1, further comprising a top finish panel.
 6. The pallet of claim 1, further comprising finishing end panels disposed on each end surface of the pallet.
 7. The pallet of claim 1, further comprising top reinforcing supports extending between adjacent said vertical supports, said top supports lying parallel to said lateral shelf.
 8. A modular pallet assembly comprising: a plurality of stackable shelves, each said shelf including a plurality of vertical supports and at least one divider extending between adjacent said vertical supports, said adjacent vertical supports being selectively spaced for receiving a desired product; wherein said vertical supports include a plurality of locking grooves and said dividers include a locking hook on each opposing end, each said locking hook engaging corresponding said locking grooves on the adjacent said vertical supports to thereby define a predetermined pallet configuration.
 9. The modular pallet assembly of claim 8, wherein said vertical supports further include a lower slot and said dividers further include a lower tab, said lower tab engaging said lower slot.
 10. The modular pallet assembly of claim 8, wherein each said shelf defines a predetermined shelf width and shelf depth, at least one of said vertical supports having a depth substantially equal to said shelf depth.
 11. The modular pallet assembly of claim 8, wherein each said shelf defines a predetermined shelf width and shelf depth, at least one of said vertical supports having a depth substantially less than said shelf depth.
 12. A method of assembling a modular pallet, said method comprising: forming a lateral shelf; forming a plurality of vertical supports; positioning said plurality of vertical supports within the lateral shelf with a desired distance between adjacent said vertical supports to receive a predetermined product; and inserting at least one divider between adjacent vertical supports to as to maintain the desired distance.
 13. The method of claim 12, wherein inserting the at least one divider includes aligning a locking hook on the divider with a locking groove on the vertical support such that the locking hook engages a wall of the locking groove.
 14. The method of claim 12 further comprising forming a pallet skirt and positioning the lateral shelf within the skirt.
 15. The method of claim 12 further comprising, after loading the predetermined product within the lateral shelf, positioning a top support between adjacent vertical supports.
 16. The method of claim 12 further comprising, after loading the predetermined product within the lateral shelf, forming at least one additional shelf and stacking the at least one additional shelf on the lateral shelf. 